Fixed mount electric actuator for marine steering system, and propulsion unit comprising the same

ABSTRACT

According to at least one embodiment, an electric actuator for a marine steering system is disclosed. The electric actuator includes a housing, an output shaft, a screw assembly coupled to the output shaft, a rotor coupled to the screw assembly, and a motor configured to rotate the rotor. Rotation of the rotor causes the output shaft to translate axially relative to the housing.

CROSS-REFERENCE TO RELATED APPLICATIONS AND CLAIM TO PRIORITY

This application is a continuation-in-part of U.S. Pat. Application No. 17/693,544 filed Mar. 14, 2022, which is a continuation of U.S. Pat. Application No. 16/789,975 filed Feb. 13, 2020, now U.S. Pat. No. 11,273,894, which claims priority to U.S. Provisional Pat. Application No. 62/805,307 filed Feb. 13, 2019 and U.S. Provisional Pat. Application No. 62/805,887, filed Feb. 14, 2019. U.S. Pat. Application No. 17/693,544, U.S. Pat. Application No. 16/789,975, U.S. Provisional Pat. Application No. 62/805,307, and U.S. Provisional Pat. Application No. 62/805,887 are all incorporated herein by reference.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to an electric actuator and, in particular, to an electric actuator for a marine steering system, as well as a propulsion unit comprising the same.

Description of the Related Art

U.S. Pat. No. 9,944,377 which was published on Apr. 17, 2018, in the name of Davidson et al., and the full disclosure of which is incorporated herein by reference, discloses a marine steering system comprising a propulsion unit including a tilt tube, a support rod received by the tilt tube, a tiller, and an electric actuator for imparting steering movement to the propulsion unit. The electric actuator includes a housing and an output shaft reciprocatingly received by the housing. The output shaft is partially threaded and has smooth surfaces. There is a motor disposed within the housing. The motor includes a stator and a rotor. Rotation of the rotor causes the output shaft to translate axially relative to the rotor and causes the output shaft to reciprocate relative to the housing. A pivot plate is pivotably connected to the tiller of the propulsion unit. The pivot plate rotationally constrains the housing of the electric actuator to provide reaction torque for rotation of the rotor. There are support arms which connect respective ends of the output shaft to the support rod of the propulsion unit. The support arms provide rotational constraint to the output shaft and the support arms inhibit axial movement of the output shaft relative to the marine vessel while the housing of the electric actuator reciprocates linearly along the output shaft.

SUMMARY OF THE INVENTION

There is provided an electric actuator for a marine steering system. The electric actuator includes a housing having a first end and second end. There is an output shaft fully received within the housing. The output shaft includes a first end, a second end, and a coupling portion disposed between the first end and the second end. There is a roller screw assembly disposed within the housing near the first end of the housing. The roller screw assembly includes a plurality of rollers and a central screw received by the rollers. The rollers are rotatable about the central screw and the central screw is coupled to the output shaft. There is a motor disposed within the housing near the first end of the housing. The motor including a stator and a rotor. The rotor has an axial bore which engages with the rollers of the roller screw assembly. Rotation of the rotor causes the roller screw assembly to translate axially relative to rotor and the output shaft to reciprocate within the housing. There may be a guide bushing disposed within the housing near the motor. The guide bushing may reciprocatingly receiving the output shaft. There may be a guide bushing disposed within the housing near the second end of the housing. The guide bushing may reciprocatingly receive the output shaft. The coupling portion of the output shaft may include a tiller extension. The motor may be concentric to the roller screw assembly.

There is also provided a propulsion unit for a marine steering system. The propulsion unit comprises an electric actuator and a tiller coupled to the electric actuator. The electric actuator includes a housing having a first end and second end. There is an output shaft fully received within the housing. The output shaft includes a first end, a second end, and a coupling portion disposed between the first end and the second end. The tiller is coupled to the coupling portion of the output shaft such that such that a line of action of the actuator is in the same plane as the tiller. There is a roller screw assembly disposed within the housing near the first end of the housing. The roller screw assembly includes a plurality of rollers and a central screw received by the rollers. The rollers are rotatable about the central screw and the central screw is coupled to the output shaft. There is a motor disposed within the housing near the first end of the housing. The motor includes a stator and a rotor. The rotor has an axial bore which engages with the rollers of the roller screw assembly. Rotation of the rotor causes the roller screw assembly to translate axially relative to the rotor and the output shaft to reciprocate within the housing. There may be a guide bushing disposed within the housing near the motor. The guide bushing may reciprocatingly receive the output shaft. There may be a guide bushing disposed within the housing near the second end of the housing. The guide bushing may reciprocatingly receive the output shaft. The coupling portion of the output shaft may include a tiller extension. The electric actuator may be bolted to the propulsion unit and an interior of the electric actuator may be sealed. The tiller may be bolted to the propulsion unit by a bolt and there may be a resilient insert about the bolt. The motor may be concentric to the roller screw assembly.

According to at least one embodiment, there is disclosed an electric actuator for a marine steering system, the electric actuator comprising: a housing; an output shaft; a screw assembly coupled to the output shaft; a rotor coupled to the screw assembly; and a motor configured to rotate the rotor, wherein rotation of the rotor causes the output shaft to translate axially relative to the housing.

In some embodiments, the output shaft is fully received within the housing.

In some embodiments, the output shaft includes a coupling portion, the coupling portion fully received within the housing and coupleable to a tiller of a propulsion unit.

In some embodiments, the coupling portion is between first and second ends of the output shaft.

In some embodiments, the coupling portion is at an end of the output shaft.

In some embodiments, the tiller is coupled to the coupling portion.

In some embodiments, the tiller has a tiller axis and is coupled to the coupling portion such that a line of action of the output shaft is in the same plane as the tiller axis throughout the entire steering range.

In some embodiments, the tiller has a tiller axis and is coupled to the coupling portion such that an axis of the output shaft intersects the tiller axis through the entire steering range.

In some embodiments, the rotor has an axial bore which engages with the screw assembly.

In some embodiments, the screw assembly comprises a drive screw, the drive screw coupled to the output shaft.

In some embodiments, the screw assembly is a roller screw assembly comprising a plurality of rollers and a central screw received by the rollers, the rollers being rotatable about the central screw and the central screw coupled to the output shaft, wherein the axial bore engages with the rollers of the roller screw assembly.

In some embodiments, the output shaft has an axial bore which engages with the screw assembly.

In some embodiments, the screw assembly is a roller screw assembly comprising a plurality of rollers and a central screw received by the rollers, the rollers being rotatable about the central screw and the central screw coupled to the rotor, wherein the axial bore engages with the rollers of the roller screw assembly.

In some embodiments, rotation of the rotor causes the screw assembly to translate axially relative to the rotor.

In some embodiments, the screw assembly is axially stationary relative to the housing.

In some embodiments, the screw assembly engages the rotor directly.

In some embodiments, the screw assembly engages the output shaft directly.

In some embodiments, the motor is concentric to the screw assembly.

In some embodiments, the motor includes a stator and the rotor.

In some embodiments, wherein the motor includes a stator and a motor shaft, the motor is configured to rotate the motor shaft, and the motor shaft is rotationally coupled to the rotor such that rotation of the motor shaft applies a torque to the rotor to cause rotation of the rotor.

According to at least one embodiment, there is disclosed a propulsion unit comprising: the electric actuator, wherein the output shaft includes a coupling portion; and a tiller coupled to the coupling portion.

In some embodiments, the coupling portion is fully received within the housing.

BRIEF DESCRIPTIONS OF DRAWINGS

The invention will be more readily understood from the following description of the embodiments thereof given, by way of example only, with reference to the accompanying drawings, in which:

FIG. 1 is a perspective view of a propulsion unit for a marine vessel and an electric actuator mounted on the propulsion unit;

FIG. 2 is a top plan view of the propulsion unit and the electric actuator of FIG. 1 ;

FIG. 3 is a perspective view of the electric actuator of FIG. 1 ;

FIG. 4 is a sectional view of the electric actuator of FIG. 1 ;

FIG. 4A is an enlarged partial sectional view of the electric actuator of FIG. 1 ;

FIG. 5 is a sectional view similar to FIG. 4 of another embodiment of an electric actuator similar to the electric actuator of FIG. 1 ;

FIG. 6 is a sectional view similar to FIG. 4 of yet another embodiment of an electric actuator similar to the electric actuator of FIG. 1 ;

FIG. 7 is a sectional view similar to FIG. 4 of a further embodiment of an electric actuator similar to the electric actuator of FIG. 1 ; and

FIG. 8 is a sectional view similar to FIG. 4 of a further embodiment of an electric actuator similar to the electric actuator of FIG. 1 .

DESCRIPTIONS OF THE PREFERRED EMBODIMENTS

Referring to the drawings and first to FIG. 1 , there is shown a propulsion unit 10 for a marine vessel (not shown). The propulsion unit 10 generally comprises a mounting bracket 12 for mounting the propulsion unit 10 to the marine vessel. The propulsion unit includes a swivel bracket assembly 14 for steering, trimming and tilting the propulsion unit 10 relative to the marine vessel. The propulsion unit 10 includes an engine 16 for powering the propulsion unit 10 and a propeller 18 for imparting a thrust to the marine vessel. There is also an electric actuator 30 which is mounted on the propulsion unit. In this example, and as best shown in FIG. 2 , the electric actuator 30 is mounted asymmetrically on the propulsion unit 10. The propulsion unit shown in FIGS. 1 and 2 is an outboard engine. However, the propulsion unit 10 may be any suitable marine propulsion unit such as, for example, an inboard engine or a stern drive.

The electric actuator 30 is shown in greater detail in FIG. 3 . The electric actuator 30 has a housing 32 which has a first end 34 and a second end 36. There is a mounting subassembly 38 extending radially relative to a longitudinal axis 110 of the electric actuator 30. The mounting subassembly includes an aperture 40 which allows access to an interior 41 of the housing 32. There is a seal 42 disposed about the aperture 40 so that the interior of the housing is sealed when the electric actuator 30 is mounted to the propulsion unit 10. The mounting subassembly 38 also includes a plurality of threaded apertures 44 a, 44 b, 44 c, and 44 d which allow the electric actuator 30 to be bolted to the propulsion unit 10 as shown in FIGS. 1 and 2 . Referring back to FIG. 3 , the mounting subassembly further includes dowel pins 46 a and 46 b which enable the electric actuator to be aligned with the propulsion unit prior to bolting the electric actuator 30 to the propulsion unit, as described above.

Referring now to FIGS. 4 and 4A, the electric actuator 30 includes an output shaft 48 which is fully received and sealed within the housing 32 when the housing is mounted to the propulsion unit 10. This protects the output shaft from the environment and reduces the need for advanced corrosion protection. The output shaft 48 includes a first end 50, a second end 52, and a coupling portion 54 disposed between the first end 50 of the output shaft 48 and the second end 52 of the output shaft 48. As shown in FIG. 4 , the coupling portion 54 is also fully received within the housing 32.

As seen in FIG. 4A, the output shaft is coupled to a roller screw assembly 56 which is disposed within the housing 32 near the first end 34 of the housing 32. The roller screw assembly includes a plurality of rollers arranged in an annular configuration, for example rollers 58 a and 58 b, and a central screw 60. The rollers are rotatable about the central screw in a planetary fashion but do not translate axially relative to the central screw. Alignment of the rollers 58 a and 58 b and the central screw 60 is maintained through the use of respective interlocking gear teeth 62 and 64 on the rollers 58 a and 58 b and the central screw 60. There are annular end plates 66 a and 66 b which hold the roller screw assembly 56 together. The end plates 66 a and 66 b are free to rotate relative to the central screw 60 and the end plates 66 a and 66 b are each provided with journal bearing bores (not shown) that allow the rollers 58 a and 58 b to rotate independently of the end plates 66 a and 66 b.

The central screw 60 is provided with an axial through bore (or axial bore) 68. A bolt 70 extends through the axial through bore of the central screw, and threadedly engages the first end 50 of the output shaft 48 to couple the roller screw assembly 56 to the output shaft 48. As a result, as shown in FIGS. 4 and 4A, the screw assembly 56 engages the output shaft 48 directly. However, in other examples, the central screw and the output shaft may be a unitary construction, such as in the form of a traditional acme screw, for example.

Still referring to FIG. 4A, there is a motor 72 disposed within the housing 32 near the first end 34 of the housing 32. The motor 72 is a DC brushless electric motor, in this example, and includes a motor shaft 73, a motor stator 74, and a motor rotor 75. The motor 72 is configured to rotate the motor shaft 73, and the motor shaft 73 is rotationally coupled to a rotor 76 such that rotation of the motor shaft 73 applies a torque to the rotor 76 to cause rotation of the rotor 76. The rotor 76 is constrained axially within the housing 32 but is able to rotate through the provision of bearings 78 a and 78 b disposed at opposite ends of the rotor 76. The rotor 76 has a threaded axially through bore 80 which threadedly engages the rollers 58 a and 58 b, thus coupling the rotor 76 to the roller screw assembly 56. As a result, as shown in FIGS. 4 and 4A, the screw assembly 56 is threadedly coupled directly (and thus engages directly) to the rotor 76. Rotation of the rotor 76 relative to the roller screw assembly 56 causes the roller screw assembly and thus the output shaft 48 to translate axially relative to the rotor and the output shaft 48 to reciprocate within the housing 32.

There is a guide bushing 82 disposed within the housing 32 near the motor 72. The guide bushing 82 reciprocatingly receives the output shaft 48. As seen in FIG. 4 , there is also a guide bushing 84 disposed near the second end 36 of housing 32. The guide bushing 84 also reciprocatingly receives the output shaft 48. There are apertures 86 a and 86 b in the guide bushing to enable or facilitate air flow between the first end of 34 of the housing 32 and a second end 36 of the housing 32 as well as through a center of the housing.

Still referring to FIG. 4 , a tiller 88 of the propulsion unit 10 is coupled to the coupling portion 54 of the output shaft 48. The tiller has a longitudinal axis 89. The guide bushings 82 and 84 support the output shaft on either side of the tiller to reduce side loads. The tiller 88 is coupled to the output shaft 48 such that line of action 120 of the output shaft of the electric actuator 30 is in the same plane as the tiller axis 89 through the entire steering range. The axis 121 of the output shaft intersects the axis of the tiller through the entire steering range. This minimizes turning moment (torque couple) on the roller screw assembly 56. This is advantageous because any torque couple causing an overturning moment to the roller screw assembly decreases efficiency and derates load carrying capacity. The tiller 88 is mounted on the propulsion unit 10 by a plurality of attachment bolts, for example attachments bolts 90 a and 90 b. Each said bolt is surrounded by a respective resilient insert, for example resilient insert 92 a and 92 b, which provide compliance. More specifically, the resilient inserts function as a safeguard against shock loading and damage to contacting surfaces.

The electric actuator 30 is also provided with manual override mechanisms. A tool (not shown) may be inserted through access port 94 to manually rotate the roller screw assembly 56 to manually reposition the propulsion unit 10. A tool (not shown) may also be inserted through access port 96 to manually rotate the motor 72 so as to manually reposition the propulsion unit 10 at a reduced ratio.

FIG. 5 shows another embodiment of an electric actuator 130. The electric actuator 130 shown in FIG. 5 is generally identical to the electric actuator shown 30 in FIGS. 1 to 4 with the notable exception that there is a tiller extension 132 mounted on the coupling portion 54. The tiller extension allows the electric actuator 130 to be mounted to any propulsion unit to provide a higher mechanical advantage. A spacer (not shown) may optionally be employed to provide an equal tiller extension amount. The spacer may be of resilient material to provide shock absorption. The tiller extension 132 or the spacer provide adjustment to fit a variety of propulsion units. For example, the electric actuator 130 may be mounted to a propulsion unit during the manufacture of the propulsion unit, or the electric actuator may be mounted to an in-service propulsion unit as a retrofit.

FIG. 6 shows another embodiment of an electric actuator 230. The electric actuator shown in FIG. 6 is similar to the electric actuator 30 shown in FIGS. 1 to 4 with the notable exception that electric actuator 230 includes a motor 272 that is concentric to the roller screw assembly 256. The motor 272 includes a stator 274 and a rotor 276 as shown in FIG. 6 . The electric actuator includes a controller 275 and an actuator position sensor, in this example a linear magnetoresistive absolute position sensor 277. The electric actuator 230 further includes a brake 279 and a chamber 281 for an additional motor and roller screw (not shown).

FIG. 7 shows a further embodiment of an electric actuator 330. The electric actuator shown in FIG. 7 is generally identical to the electric actuator 30 shown in FIGS. 1 to 4 with the notable exception that instead of resilient inserts 92 a and 92 b, the coupling portion 354 is made of resilient material to provide similar shock absorption.

FIG. 8 shows another embodiment of an electric actuator 430. The electric actuator 430 shown in FIG. 8 is similar to the electric actuator 30 shown in FIGS. 1 to 4A, although the electric actuator 430 has an internally threaded output shaft 448 and a rotor 476. Additionally, instead of the axially translating roller screw assembly 56 of the electric actuator 30, the electric actuator 430 has a roller screw assembly 456 that may be axially stationary relative to a housing 432 of the electric actuator 430. The output shaft 448 is fully received and sealed within the housing 432.

More specifically, the output shaft 448 of the electric actuator 430 has an axially threaded through bore (or axial bore) 449, and the roller screw assembly 456 includes rollers, such as rollers 458 a and 458 b, which threadedly engage internal threads surrounding the through bore 449. As a result, the screw assembly 456 is threadedly coupled directly to (and thus engages directly) the axial bore 449 and the output shaft 448. The roller screw assembly 456 also includes a central screw 460 which is received by the rollers 458 a and 458 b. The rollers 458 a and 458 b are rotatable about the central screw 460, and the central screw 460 is coupled to a first end 477 of the rotor 476. For example, the central screw 460 may be threadedly coupled directly to the first end 477 of the rotor 476. As a result, the screw assembly 456 is threadedly coupled directly to the rotor 476 and engages the rotor 476 directly. The rotor 476 is constrained axially within the housing 432 but is able to rotate relative to the housing 432 through the provision of a bearing 478 disposed at a second end 483 of the rotor 476. Because the central screw 460 is coupled to the rotor 476, the roller screw assembly 456 is also constrained axially but able to rotate.

The electric actuator 430 further includes a motor 472 which has a motor shaft 473. The motor 472 is configured to rotate the motor shaft 473, and the motor shaft 473 is rotationally coupled to the rotor 476 such that rotation of the motor shaft 473 applies a torque to the rotor 476 to cause rotation of the rotor 476. Rotation of the rotor 476 causes the rollers 458 a and 458 b of the roller screw assembly 456 to rotate, and, in turn, rotation of the rollers 458 a and 458 b relative to the output shaft 448 causes the output shaft 448 to translate axially relative to the roller screw assembly 456 and the rotor 476, thus causing the output shaft 448, including a coupling portion 454 of the output shaft 448, to reciprocate within the housing 432. The coupling portion 454 is also fully received within the housing 432 and disposed between first and second ends of the output shaft 448. A tiller (such as the tiller 88) of a propulsion unit may be coupled to the coupling portion 454 as described above, and reciprocation of the output shaft 448 within the housing 432 may therefore exert a force on the tiller to steer the propulsion unit.

The roller screw assembly 456 and other components of the electric actuator 430 may include materials which are not inherently corrosion resistant. Accordingly, in the embodiment shown in FIG. 8 , the electric actuator 430 further includes a corrosion resistant tube 451 surrounding the output shaft 448. However, alternative embodiments may not include a corrosion resistant tube.

It will be understood by a person skilled in the art that while the electric actuators disclosed herein comprise a roller screw assembly, in other examples, the electric actuator may comprise any suitable screw assembly with a drive screw. It will also be understood by a person skilled in the art that many of the details provided above are by way of example only, and are not intended to limit the scope of the invention which is to be determined with reference to the following claims. 

What is claimed is:
 1. An electric actuator for a marine steering system, the electric actuator comprising: a housing; an output shaft; a screw assembly coupled to the output shaft; a rotor coupled to the screw assembly; and a motor configured to rotate the rotor, wherein rotation of the rotor causes the output shaft to translate axially relative to the housing.
 2. The electric actuator of claim 1 wherein the output shaft is fully received within the housing.
 3. The electric actuator of claim 1 wherein the output shaft includes a coupling portion, the coupling portion fully received within the housing and coupleable to a tiller of a propulsion unit.
 4. The electric actuator of claim 3 wherein the coupling portion is between first and second ends of the output shaft.
 5. The electric actuator of claim 3 wherein the coupling portion is at an end of the output shaft.
 6. In combination, the electric actuator of claim 3 and the tiller, wherein the tiller is coupled to the coupling portion.
 7. The combination of claim 6 wherein the tiller has a tiller axis and is coupled to the coupling portion such that a line of action of the output shaft is in the same plane as the tiller axis throughout the entire steering range.
 8. The combination of claim 6 wherein the tiller has a tiller axis and is coupled to the coupling portion such that an axis of the output shaft intersects the tiller axis through the entire steering range.
 9. The electric actuator of claim 1 wherein the rotor has an axial bore which engages with the screw assembly.
 10. The electric actuator of claim 9 wherein the screw assembly comprises a drive screw, the drive screw coupled to the output shaft.
 11. The electric actuator of claim 9 wherein the screw assembly is a roller screw assembly comprising a plurality of rollers and a central screw received by the rollers, the rollers being rotatable about the central screw and the central screw coupled to the output shaft, wherein the axial bore engages with the rollers of the roller screw assembly.
 12. The electric actuator of claim 1 wherein the output shaft has an axial bore which engages with the screw assembly.
 13. The electric actuator of claim 12 wherein the screw assembly is a roller screw assembly comprising a plurality of rollers and a central screw received by the rollers, the rollers being rotatable about the central screw and the central screw coupled to the rotor, wherein the axial bore engages with the rollers of the roller screw assembly.
 14. The electric actuator of claim 1 wherein rotation of the rotor causes the screw assembly to translate axially relative to the rotor.
 15. The electric actuator of claim 1 wherein the screw assembly is axially stationary relative to the housing.
 16. The electric actuator of claim 1 wherein the screw assembly engages the rotor directly.
 17. The electric actuator of claim 1 wherein the screw assembly engages the output shaft directly.
 18. The electric actuator of claim 1 wherein the motor is concentric to the screw assembly.
 19. The electric actuator of claim 1 wherein the motor includes a stator and the rotor.
 20. The electric actuator of claim 1 wherein the motor includes a stator and a motor shaft, the motor is configured to rotate the motor shaft, and the motor shaft is rotationally coupled to the rotor such that rotation of the motor shaft applies a torque to the rotor to cause rotation of the rotor.
 21. A propulsion unit comprising: the electric actuator of claim 1, wherein the output shaft includes a coupling portion; and a tiller coupled to the coupling portion.
 22. The propulsion unit of claim 21 wherein the coupling portion is fully received within the housing. 